Abstract: Porous plasma arc sprayed powder metal abradable materials used in knife edge labyrinth seals of gas turbine engines have their resistance to erosion improved when a thin ceramic surface layer containing fine aluminum particulate is applied. The fine equiaxed particulate and ceramic are applied as an aqueous liquid so that both the particulate and cermic matrix material fill the surface pores, without penetrating further into the powder metal material and thereby adversely affecting desirable abradability characteristics.
Abstract: A protective coating system for superalloys is described. The coating is an active element enriched aluminide, and can be formed by aluminizing an overlay coated superalloy, wherein during the aluminizing process, aluminum diffuses completely through the overlay coating and into the substrate. The coating system exhibits desirable oxidation resistance and resistance to thermal fatigue cracking, due to the presence of oxygen active elements in the overlay.